Bronze Six Pack

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Bronze Six Pack

• Emily Braun, Craig Lang, Michael Lawrence, Shawn
  Martin, Lauren Snedeker

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Introduction

• Objective To sand cast two solid bronze coke
  bottles simultaneously
• Gating system was designed to maintain aesthetic
  integrity
• Mold was made to produce minimal defects

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Bronze

• Copper alloy
• 90 Copper, 5 Tin, 5 Zinc
• Higher strength and lower melting point than
  copper
• Liquidus temperature of bronze is 1010C,
  compared to 1084C for copper

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Experimental Methods

• Modeled in Ideas
• Designed gating system
• Predicted porosity with Magmasoft
• Constructed patterns
• Made sand mold
• Poured

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Magmasoft Cooling Rate
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Magmasoft Porosity
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Magmasoft Fill Modeling
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Magmasoft FillingTime
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Magmasoft Solidification Time
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Coca-Cola Pattern

• Abrasive water-jet cutting of glass bottles
• Several attempts to produce draft angles
• Epoxy failed
• Bondo failed
• JB Weld success!!!
• Fabricated pattern board

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Sand Mold

• Oil-bonded sand
• Carved gating system after ramming

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Bronze Pouring

• Poured at approximately 1200C
• Flame was green

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Post-Pour
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Final Casting

• Detail better than expected
• Porosity due to shrinkage as predicted
• Casting Yield 60-65
• Heavy!!!

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Retrospect

• Research epoxy before application
• Needed riser to prevent shrinkage
• Could have painted wood pattern to prevent sand
  sticking

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Conclusion

• Successfully cast two bronze
• coca-cola bottle replicas